Manufacturing & Industrial IoT Solutions

Smart Manufacturing & Industrial IoT

Drive Industry 4.0 transformation with smart manufacturing solutions. From IoT integration to predictive maintenance, we build systems that optimize production and reduce downtime.

23+
Manufacturing Projects
45%
OEE Improvement
30%
Downtime Reduction
$8M+
ROI Achieved

Industry Challenges

Unique challenges that require specialized software solutions

Legacy Equipment Integration

Connecting modern IoT systems with decades-old manufacturing equipment.

Unplanned Downtime

Equipment failures causing costly production delays and maintenance.

Data Silos

Fragmented data across different systems preventing holistic insights.

Quality Consistency

Maintaining consistent product quality across shifts and production lines.

Our Software Solutions

Comprehensive development services designed to meet unique industry needs

Industrial IoT & Sensor Integration

Connect machines, sensors, and equipment for real-time monitoring and data collection.

Key Features:

Sensor Integration
Real-time Monitoring
Edge Computing
Protocol Support

Technologies:

MQTTOPC UAModbusIndustrial IoTTime Series DB

Predictive Maintenance Systems

ML-powered systems that predict equipment failures before they occur, reducing downtime.

Key Features:

Failure Prediction
Maintenance Scheduling
Asset Tracking
Condition Monitoring

Technologies:

PythonMachine LearningTime Series AnalysisApache KafkaInfluxDB

Manufacturing Execution Systems (MES)

Track and document the transformation of raw materials to finished goods in real-time.

Key Features:

Production Tracking
Quality Management
Inventory Control
Work Orders

Technologies:

JavaSpring BootPostgreSQLREST APIsIndustrial Protocols

Digital Twin Development

Create virtual replicas of physical assets for simulation, optimization, and predictive analysis.

Key Features:

Virtual Modeling
Simulation
Performance Optimization
Scenario Testing

Technologies:

Unity3DIoT IntegrationMachine LearningCloud Computing3D Modeling

Success Stories

Real results from our industry projects

Smart Factory Optimization Platform

Challenge:

A manufacturer struggled with low Overall Equipment Effectiveness (OEE) and frequent unplanned downtime.

Solution:

We implemented an IIoT platform with predictive maintenance, real-time monitoring, and production optimization algorithms.

Results:

  • 45% improvement in OEE
  • 30% reduction in downtime
  • 25% energy savings achieved
  • $8M+ ROI in first year
Technologies Used:
Industrial IoTPythonMachine LearningTime Series DBAzure IoT

Predictive Maintenance System

Challenge:

Unexpected equipment failures were causing production losses and food safety risks.

Solution:

We developed a predictive maintenance system using sensor data and machine learning to forecast failures 2-4 weeks in advance.

Results:

  • 60% reduction in unplanned downtime
  • 40% decrease in maintenance costs
  • 95% prediction accuracy
  • Zero food safety incidents
Technologies Used:
PythonTensorFlowMQTTInfluxDBGrafana

Why Choose DevSimplex?

We understand the unique challenges and have the expertise to deliver secure, compliant, and scalable solutions.

  • 23+ manufacturing projects across diverse industries
  • Industry 4.0 and smart factory expertise
  • Industrial protocol specialists (OPC UA, Modbus, MQTT)
  • Predictive maintenance algorithm development
  • Edge computing and real-time processing
  • ISO 9001 and IEC 62443 compliance knowledge

Industry Certifications

ISO 9001
Quality
IEC 62443
Security
OPC UA
Certified
AWS IoT
Specialist

Our Development Process

A specialized approach with compliance and security built into every step

01

Manufacturing Assessment

Analyze production processes, equipment, data sources, and identify optimization opportunities.

02

IoT Architecture Design

Design sensor network, edge computing infrastructure, and data pipeline architecture.

03

System Development & Integration

Develop and integrate IoT sensors, predictive models, and manufacturing systems.

04

Deployment & Optimization

Phased rollout with training, monitoring, continuous improvement, and ROI tracking.

Frequently Asked Questions

How do you integrate with legacy manufacturing equipment?

We use industrial protocols (OPC UA, Modbus, Profinet), edge gateways, and retrofit sensors to connect legacy equipment. We can interface with PLCs, SCADA systems, and older machinery without disrupting production.

What is predictive maintenance and how accurate is it?

Predictive maintenance uses sensor data and machine learning to forecast equipment failures before they occur. Our systems typically achieve 90-95% accuracy, predicting failures 2-4 weeks in advance, allowing planned maintenance during scheduled downtime.

Can you integrate MES with our existing ERP system?

Yes, we have extensive experience integrating MES with major ERP systems (SAP, Oracle, Microsoft Dynamics) through APIs, middleware, and data synchronization. We ensure seamless data flow between shop floor and business systems for real-time visibility.

What ROI can we expect from smart manufacturing initiatives?

Typical ROI ranges from 200-400% within 18-24 months. Benefits include reduced downtime (20-40%), improved OEE (15-45%), lower maintenance costs (30-50%), energy savings (15-30%), and better quality control. We provide detailed ROI analysis during planning.

Ready to Transform Your Manufacturing?

Let's build a smart factory solution that optimizes production, reduces costs, and drives Industry 4.0 transformation.